Grounding method for eliminating process antenna effect

Abstract: A method for eliminating the antenna effect in the manufacture of an integrated circuit in a silicon substrate, wherein there are contact pad areas at the periphery of the integrated circuit and interconnection lines connecting the contact pad areas with the integrated circuit. This is achieved by grounding the contact pad areas to the silicon substrate; processing in a plasma environment that would normally produce electrical charge build-up at the gate oxide of the integrated circuit, but wherein the grounded contact pad areas eliminates the charge build-up; and disabling the grounding of the contact pad areas to retrieve the functioning of the integrated circuit.

Description: The present invention relates to the manufacture of highly dense integrated circuits, and more particularly to the elimination of electrostatic charge build-up at the device during manufacture during, for example, plasma etching or the like process steps. In the manufacture of highly dense integrated circuits using Metal Oxide Semiconductor (MOS) technology with multiple metal layers, electrical charge may build up at the device gate oxide during plasma processing. The charge accumulates on floating polysilicon and metal layers electrically connected to the gate oxide. Interconnection metal lines act as an "antenna", amplifying the charging effect and leading to trapped charges at the gate oxide. These trapped charges can cause yield loss and reliability failures. Workers in the field have verified this problem experimentally. It has been found that the double metal layer technologies worsen the effect by the ratio of the antenna area to the gate oxide area. The worst degradation of gate oxide occurs during oxynitride deposition. However other plasma processing is also believed to lead to trapped charges at the gate oxide. Referring now to Figs. 1A and 1B, there are shown schematic diagrams of a prior process for connecting a large contact pad with an active MOS device by using a metal layer, which could lead to device damage due to the antenna effect. As can be seen in Fig. 1A, in the manufacture of MOS semiconductor devices, a large contact pad area 10 (of typical size 100 by 100 micrometers, and more than about 30 by 30 micrometers) is electrically connected by vias 12 to a polysilicon interconnection 14. The pad area 10 in a double metal process would consist of two layers 24 and 26 of metal, as shown in Fig. 1B. The upper metal layer, or metal II, 26 is connected through an insulating layer 28 to the lower metal layer, or metal I, 24 by a large via 25 which generally has a size less than 5 micrometers smaller than the large contact pad area 10. The polysilicon interconnection 14 is connected by vias 16 in an insulating layer to metal interconnection 18. This metal interconnection 18 is connected by vias 17 to polysilicon 20 and thence to active devices 22. There is a direct electrical connection between all elements, and charge accumulated during plasma processing on the polysilicon and large metal areas can lead to damage to the devices due to trapped charges. More specifically, charge will be induced and accumulated on the exposed lower metal layer 24 through the large via 25 in the pre-sputter etching step before the upper metal layer 26 is sputtered. The induced charge can lead to damage to the devices 22 via the direct electrical connection path, comprising the lower metal layer 24, the polysilicon interconnection 14, the metal interconnection 18 and the polysilicon 20. In addition, the greater the size of the large via 25, the greater the amount of the charge induced and accumulated. It is common in the manufacture of integrated circuits today to use plasma etching, plasma enhanced chemical vapor deposition, and sputtering technologies. See VLSI Technology, S. M. Sze., Chapter 5 - Reactive Plasma Etching pages 184-189, Chapter 6 - Dielectric and Polysilicon Film Deposition pages 235-238, Chapter 9 - Metallization pages 386-391, published by McGraw-Hill International Editions 1988 in Singapore. A plasma is a collection of charged particles, including electrons and positive and negative ions, and it is these charged particles that collect along the conductive surfaces during plasma processing, and may produce the trapped charges damaging the gate oxide. Therefore, the primary object of the present invention is to provide a grounding method for eliminating the antenna effect of accumulated electrical charge on floating polysilicon, metal interconnections, and contact pads connected to the gate oxide, without additional process steps. This is accomplished by providing, prior to plasma processing dummy lines to electrically connect the contact pads to the substrate and thereafter breaking the connection. US-A-4941028 discloses a technique of protecting a dielectric in an integrated circuit from damage due to static charge build-up during processing. This involves connecting a transistor in series with a conductor overlying the dielectric so that the transistor gate accumulates charge as well as the conductor. When the charge exceeds the threshold voltage the transistor turns on and the charge is discharged by the source thus protecting the dielectric. After fabrication and during normal circuit operation the transistor remains in its off state. The charge is not removed unless it exceeds the threshold voltage. Also, the parasitic capacity between the source and substrate restricts the speed of the device. EP-A-510900 describes an MOS integrated circuit which includes an ESD circuit to provide protection against the electrostatic charges frequently carried by persons handling such devices. The ESD circuit is connected to the MOS circuit by a link which can be broken, after installation, by the application of heat. US-A-4714949 describes a technique for protecting a mercury-cadmium telluride MIS array against electrostatic discharges across the dielectric during array fabrication. This involves forming a novel gate structure whereby a continual short circuit from the gate structure to the substrate is provided during processing. Any charge build-up on the gate structure is dissipated to the substrate via the short circuit. The gate structure includes a region of reduced cross-section which can be melted by the application of an appropriate voltage after the array has been completed. EP-A-0431490 describes a semiconductor integrated circuit device having an improved arrangement of pads. The device includes a semiconductor chip including internal circuits, pads disposed at the periphery of the semiconductor chip and arranged in at least first and second rows, and multilevel interconnection means for electrically connecting the internal circuits to the pads. In Symp. VLSI Tech May 89, pages 73-74, Shone et al. describe techniques for eliminating gate oxide charging. These techniques include subjecting the wafers to longer alloy cycles, depositing a thin dielectric layer on the wafer before oxynitride deposition, and attaching a substrate diode to the antenna. There is no suggestion to reduce gate oxide charging by temporarily connecting contact pad areas to the substrate during plasma processing. Moreover there is no disclosure of contact pads at the device periphery. According to the present invention, there is provided a method of eliminating the antenna effect occurring in the manufacture of an integrated circuit in a silicon substrate when processing in a plasma environment that would normally produce electrical charge build-up at the gate oxide of the integrated circuit, characterized in that there are provided contact pad areas at the periphery of the integrated circuit, interconnection lines connecting the contact pad areas with the integrated circuit, a power rail connected to the substrate, and a power pad area connected to the power rail; in that the method includes, prior to said plasma processing, depositing and patterning a first layer of metal at least to form dummy lines not needed for normal functioning of the integrated circuit, which respectively connect the contact pad areas with the power rail so that the contact pad areas are grounded to the silicon substrate and so that the charges produced during the subsequent plasma processing are discharged to the substrate; and in that the dummy lines are subsequently broken so that the contact pad areas are no longer electrically connected to the power rail whereby the integrated circuit functions normally. In accordance with an embodiment of the present invention, the method includes: forming a diffusion region in the silicon substrate; forming an insulating layer on the silicon substrate with at least one opening to the diffusion region; and depositing and patterning the above-mentioned first layer of metal on the insulating layer to form the contact pad areas, the interconnection lines, the power rail at least connected to the diffusion region of the substrate through the opening in the insulating layer, the power pad area connected to the power rail, and the dummy lines respectively connecting the contact pad areas with the power rail, thereby grounding the contact pad areas to the silicon substrate via the dummy lines, power rail and diffusion region. In accordance with another embodiment of the present invention, the dummy lines are broken by applying a predetermined voltage alternately across each one of the contact pad areas and the power pad area to burn out the dummy lines so that the contact pad areas are disconnected from the power rail. In accordance with an alternative embodiment of the present invention, the dummy lines are broken by: forming a second insulating layer on the first metal layer with openings to the contact pad areas and the dummy lines; depositing a second layer of metal on the second insulating layer such that the second metal layer is connected to the contact pad areas and dummy lines through the openings in the second insulating layer; forming a resist material over the contact pad areas; removing the uncovered second metal layer, and then removing the uncovered dummy lines in order to disconnect the contact pad areas from the power rail; and removing the resist material whereby the residual second metal layer with the first metal layer in the contact pad areas forms the eventual contact pads of the integrated circuit. The processing in the plasma environment may be plasma enhanced chemical vapor deposition, plasma etching, or sputter etch. The method of the present invention can be applied to multi-level metal technology in a similar way to that described above. For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which: Figs. 1A and 1B illustrate a prior process for connecting a large contact pad with an active MOS device by using a metal layer, which could lead to device damage due to the antenna effect, Fig. 2 illustrates a schematic diagram of an integrated circuit layout for eliminating the antenna effect according to the method of the present invention by using grounded dummy metal lines which are connected to the large contact pads respectively, Fig. 3A illustrates a cross-sectional representation of a power pad area taken along the line 3A-3A shown in Fig. 2, Fig. 3B illustrates a cross-sectional representation of a contact pad area with a grounded dummy metal line, taken along the line 3B-3B shown in Fig. 2, and Figs. 4A and 4B illustrate a further embodiment of the present invention for cutting off the dummy metal lines after plasma processing steps are finished. Referring now to Fig. 2, there is shown a new layout design for an integrated circuit (IC) 30 in a silicon substrate according to one preferred embodiment of the present invention, wherein there is a power rail 40, a power pad area 38, and large contact pad areas 32 at the periphery of the integrated circuit 30. The power rail 40 is connected directly to the power pad area 38 and to a diffusion region 42 in the silicon substrate through contacts 44. The power pad area 38 connects to the power pin V DD or V SS of the finished IC chip. Each contact pad area 32 is connected to the integrated circuit 30 via an interconnection line 34 and to the power rail 40 via a dummy line 36. All of the interconnection lines 34, contact pads 32, dummy lines 36, power rail 40, power pad 38, and contacts 44 can be formed by a first metal. According to this layout design, any charge accumulated during plasma processing steps on the conductive layers, particularly on the large contact pad areas 32, can be discharged to the grounded silicon substrate via a direct electrical connection path from the contact pad areas 32, dummy lines 36, power rail 40, and contacts 44 to the diffusion region 42. This method, thus, effectively and completely eliminates the antenna effect. After the integrated circuit is finished and before testing, an appropriate voltage can be applied alternately across each one of the contact pads 32 and the power pad 38 to burn out the dummy lines 36. Then, the functioning of the integrated circuit is retrieved without any extra IC processing steps. In order to make sure that the dummy lines 36 can be burned out without damaging any other interconnections, the dummy lines 36 are preferably formed sufficiently narrower than the other interconnections. Referring now to Figs. 3A and 3B, Fig. 3A shows a cross-sectional representation of the structures of the power pad 38, power rail 40, and diffusion region 42, taken along the line 3A-3A shown in Fig. 2, and Fig. 3B shows a cross-sectional representation of the structures of the power rail 40, dummy line 36, contact pad 32, and interconnection line 34, taken along the line 3B-3B shown in Fig. 2. Field oxide (FOX) 52 is thermally grown on the substrate 50, and the diffusion region 42 is formed in the substrate 50. BPSG (borophosilicate) insulating layer 54 is deposited and patterned on the field oxide 52 to form contact vias 56 above the diffusion region 42. A layer of metal 58 is deposited and patterned to form the power rail 40, power pad 38, dummy lines 36, contact pads 32, and interconnection lines 34. The power rail 40 is connected to the diffusion region 42 through the contact vias 56. Subsequent plasma processing steps may be completed without accumulating charge and causing the antenna effect because the metal layer 58 is grounded to the substrate 50 in this situation. Pad openings 60 are patterned through a passivation layer 62. The burning out process for the dummy lines 36 can be then performed by applying an appropriate voltage alternately across each one of the contact pads 32 and the power pad 38 in order to retrieve the functioning of the integrated circuit. It will be understood by those skilled in the art that this method can also be applied to multi-level metal technology. Referring now to Figs. 4A and 4B, there is shown in cross section another embodiment of the present invention for disconnecting the dummy lines 36 with the power rail 40 in a double metal process after plasma processing steps are finished. Referring first to Fig. 4A, field oxide (FOX) 52 is thermally grown on the substrate 50, and the BPSG (borophosilicate) insulating layer 54 is deposited and patterned on the field oxide 52. A first layer of metal 58 is deposited and patterned to form the power rail 40, dummy lines 36, contact pads 32, and interconnection lines 34 as in the above-described embodiment. Subsequent plasma processing steps may be completed without accumulating charge and causing the antenna effect because the first metal layer 58 is grounded to the substrate 50 in this situation. Vias 76 and 78 respectively above the contact pads 32 and dummy lines 36 are patterned through a second insulating layer 70. A second layer of metal 72 is deposited, and a photoresist 80 is formed to cover the pad areas. Then, the exposed second metal layer is removed by etching, and the thus-exposed dummy metal lines 36 through the vias 78 is also etched away to disconnect the contact pads 32 from the power rail 40, as shown in Fig. 4B. In this way, the functioning of the integrated circuit is retrieved without any extra processing steps. The second metal layer 72 in the pad areas is connected to the first metal layer 58 through the vias 76 to finish the eventual contact pads. After the photoresist 80 is stripped, a passivation layer 74 is deposited and patterned to form pad openings 90. It will be understood by those skilled in the art that this method can be also applied to triple- or greater multi-level metal technology.

Claims: A method of eliminating the antenna effect occurring in the manufacture of an integrated circuit (30) in a silicon substrate (50) when processing in a plasma environment that would normally produce electrical charge build-up at the gate oxide of the integrated circuit, characterized in that there are provided contact pad areas (32) at the periphery of the integrated circuit, interconnection lines (34) connecting the contact pad areas with the integrated circuit, a power rail (40) connected to the substrate, and a power pad area (38) connected to the power rail; in that the method includes, prior to said plasma processing, depositing and patterning a first layer of metal (58) at least to form dummy lines (36) not needed for normal functioning of the integrated circuit, which respectively connect the contact pad areas with the power rail so that the contact pad areas are grounded to the silicon substrate and so that the charges produced during the subsequent plasma processing are discharged to the substrate; and in that the dummy lines are subsequently broken so that the contact pad areas are no longer electrically connected to the power rail whereby the integrated circuit functions normally. The method as claimed in claim 1, including the steps of: forming a diffusion region (42) in the silicon substrate; forming an insulating layer (54) on the silicon substrate with at least one opening (56) to the diffusion region; and depositing and patterning said first layer of metal (58) on the insulating layer to form the contact pad areas (32), the interconnection lines, the power rail (40) at least connected to the diffusion region (42) of the substrate through the opening in the insulating layer, the power pad area (38) and the dummy lines (36). The method as claimed in claim 2, wherein the dummy lines are broken by applying a predetermined voltage alternately across each one of the contact pad areas (32) and the power pad area (38) to burn out the dummy lines (36) so that the contact pad areas (38) are disconnected from the power rail (40). The method as claimed in claim 2, wherein the dummy lines (36) are broken by: forming a second insulating layer (70) on the first metal layer with openings to the contact pad areas (32) and dummy lines (36); depositing a second layer of metal (72) on the second insulating layer such that the second metal layer is connected to the contact pad areas (32) and dummy lines (36) through the openings in the second insulating layer; forming a resist material (80) over the contact pad areas; removing the uncovered second metal layer (72) and then removing the uncovered dummy lines (36) in order to disconnect the contact pad areas (32) from the power rail (40); and and removing the resist material (80) whereby the residual second metal layer (72) with the first metal layer (58) in the contact pad areas (32) forms the eventual contact pads of the integrated circuit. The method as claimed in any preceding claim, wherein the processing in the plasma environment is plasma enhanced chemical vapor deposition. The method as claimed in any preceding claim, wherein the processing in the plasma environment is plasma etching. The method as claimed in claim 6, wherein the plasma etching is a sputter etch.

Inventors: KO JOE, KO,JOE
Applicants: UNITED MICROELECTRONICS CORP, UNITED MICROELECTRONICS CORPORATION
Application year: 1994
Main classification: H01L27
IPC codes: H01L27